Computational modelling of SLM additive manufacturing of metals

被引:1
作者
Chaudhry, Shubham [1 ]
Tchouambe, J. W. Tcheumanak Chuitcheu I., V [1 ]
Soulaimani, Azzeddine [1 ]
Das, Rajeev [1 ]
机构
[1] Ecole Technol Super, Dept Mech Engn, Montreal, PQ H3C 1K3, Canada
关键词
selective laser melting; SLM; simulation; additive manufacturing; ANSYS-additive; FINITE-ELEMENT-ANALYSIS; SURFACE-ROUGHNESS; RESIDUAL-STRESSES; HEAT-TRANSFER; POWDER BED; LASER; SIMULATION; TEMPERATURE; TI-6AL-4V; STAINLESS;
D O I
10.1504/IJMR.2022.127090
中图分类号
T [工业技术];
学科分类号
08 ;
摘要
Additive manufacturing (AM) is a technology that can create 3D structures by depositing or melting material in a layer-by-layer manner. This paper focuses on the metal-based powder bed fusion AM approach, specifically the selective laser melting (SLM) technique. The repetitive hot and cold cycles associated with AM, causes localised compression and tension giving rise to significant residual stresses, which can lead to shape loss, structural failure, etc. Numerous parameters determine the thermal gradient; these include the thermal characteristics of the powder, the bed temperature, and the part size. This investigation describes the associated problem formulation and numerical resolution in the SLM simulation. An ANSYS-additive model is developed to determine the parameter dependence on the process. An efficient parameter calibration algorithm is proposed to generate an accurate numerical model. Three numerical studies are conducted using a vertical prism, a horizontal prism, and an L-shaped structure also compared with the experimental data. [Submitted 25 July 2020; Accepted 10 December 2020]
引用
收藏
页码:389 / 421
页数:34
相关论文
共 50 条
[31]  
Neugebauer Fabian., 2014, PROC FRAUNHOFER DIRE, P297
[32]   A Generalized Feed-Forward Dynamic Adaptive Mesh Refinement and Derefinement Finite-Element Framework for Metal Laser Sintering-Part II: Nonlinear Thermal Simulations and Validations [J].
Pal, Deepankar ;
Patil, Nachiket ;
Kutty, Khalid Haludeen ;
Zeng, Kai ;
Moreland, Alleyce ;
Hicks, Adam ;
Beeler, David ;
Stucker, Brent .
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME, 2016, 138 (06)
[33]   On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting [J].
Panwisawas, C. ;
Qiu, C. L. ;
Sovani, Y. ;
Brooks, J. W. ;
Attallah, M. M. ;
Basoalto, H. C. .
SCRIPTA MATERIALIA, 2015, 105 :14-17
[34]   A Generalized Feed Forward Dynamic Adaptive Mesh Refinement and Derefinement Finite Element Framework for Metal Laser Sintering-Part I: Formulation and Algorithm Development [J].
Patil, Nachiket ;
Pal, Deepankar ;
Rafi, H. Khalid ;
Zeng, Kai ;
Moreland, Alleyce ;
Hicks, Adam ;
Beeler, David ;
Stucker, Brent .
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME, 2015, 137 (04)
[35]   On the role of melt flow into the surface structure and porosity development during selective laser melting [J].
Qiu, Chunlei ;
Panwisawas, Chinnapat ;
Ward, Mark ;
Basoalto, Hector C. ;
Brooks, Jeffery W. ;
Attallah, Moataz M. .
ACTA MATERIALIA, 2015, 96 :72-79
[36]   Thermomechanical finite element simulations of selective electron beam melting processes: performance considerations [J].
Riedlbauer, Daniel ;
Steinmann, Paul ;
Mergheim, Julia .
COMPUTATIONAL MECHANICS, 2014, 54 (01) :109-122
[37]   A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing [J].
Roberts, I. A. ;
Wang, C. J. ;
Esterlein, R. ;
Stanford, M. ;
Mynors, D. J. .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 2009, 49 (12-13) :916-923
[38]   Simulation of metallic powder bed additive manufacturing processes with the finite element method: A critical review [J].
Schoinochoritis, Babis ;
Chantzis, Dimitrios ;
Salonitis, Konstantinos .
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE, 2017, 231 (01) :96-117
[39]   Surface roughness analysis, modelling and prediction in selective laser melting [J].
Strano, Giovanni ;
Hao, Liang ;
Everson, Richard M. ;
Evans, Kenneth E. .
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 2013, 213 (04) :589-597
[40]  
Sun M.S., 1991, 1991 INT SOLID FREEF